chair Project: Building the chair

02a

02b

Curved
Back and Seat
Supports
01. Print the paper patterns that are
included with the chair plan.

03

03. Apply patterns to hardboard using

spray adhesive.

05

05. Sand the hardboard template to

final size.

02. Tape paper patterns together in numerical (1 through 4 for the seat support) and
alphabetical (A through D for the back support) order and trim with scissors.

04a

04b

04. Cut along the pattern lines using a bandsaw and/or jigsaw. (Note: If using a bandsaw
to make the cuts, youll have to use a jigsaw or handsaw to complete the notch on the
back support.)

06

06. Trace the hardboard templates onto

cedar boards to make two seat supports
and two back supports.

07

07. Cut along the traced lines using a bandsaw and/or jigsaw. (Note: Once again,
youll need to cut the notch on the back
support using a hand saw or jigsaw.)

chair Project: Building the chair

08a

08b

Seat Slats,
Back Slats,
Supports
08. Rip and crosscut the rectangular seat slats, back slats, and braces to size using a table
saw and miter saw. Rip and crosscut a blank for the angular top back slat.

09

09. Lay out the angled top edges on the

back slat according to the dimensions
in the project plan.

12

12. Cut between the holes using a jigsaw to

complete the handhold.

10

10. Lay out the location of the handhold

on the top back slat blank.

13

13. Cut the top back slat to shape using a

jigsaw or band saw.

11

11. Drill holes at the indicated locations to

create the ends of the handhold.

14

14. Sand.

chair Project: Building the chair

15

16

Assembly

15. Before beginning assembly, roundover

the edges of all the chair pieces using a
router table and 1/4-inch roundover bit.

17

18

17. Cut spacer blocks from plywood to help align and position the curved supports during
assembly. Clamp the spacer blocks between the curved support pieces.

19a

19b

19. Attach slats to curved supports using glue and woodscrews.

21

21. Fill each counterbore with a wood plug.

16. Now drill counterbores in all of the

seat and back slats and braces to accept
woodscrews.

22

22. Allow glue to dry on the plugs before

trimming them flush.

18. Drill pilot holes through the counterbores and into the curved supports.

20

20. Use a drill press and plug cutter to

make wood plugs.

23

23. Sand all of the chair surfaces.

24. Apply exterior finish.

chair Project: project plans

1 3/8
8 1/2

7 1/2
3

R5/8

20

2 1/4

2 1/4

1/2

20

2 1/4

1/2

2 1/2

3 1/2

2 1/2

16 1/2

9 5/8
14 1/2

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chair Project: project plans

chair Project: Template

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2 1/2

35 1/4

35 3/8

2 1/8

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